Carton forming machine



1965 w. B. FAHRENBACH ETAL 3,200,718

CARTON FORMING MACHINE 9 Sheets-Sheet 1 Filed Nov. 14, 1962 WNJINVENTORS Attorneys Wolfgang B. Fahrenbach BY Fred E. Helmick w. B.FAHRENBACH ETAL 3,200,718

CARTON FORMING MACHINE Filed Nov. 14, 1962 9 Sheets-Sheet 2 INVENTORSWolfgang B. Fahrenbach BY Fred E, Helmick Attorneys 1965 w. B.FAHRENBACH ETAL 3,200,718

CARTON FORMING MACHINE 9 Sheets-Sheet 3 Filed Nov. 14, 1962 INVENTORSWolfgang B. Fahrenbach BY Fred E. Helmick Attorneys g 1955 w. B.FAHRENBACH ETAL 3,200,718

CARTON FORMING MACHINE Filed Nov. 14, 1962 9 Sheets-Sheet 4 INVENTORSWolfgang B. Fahrenbach BY Fred E. Helmick Attorneys 1965 w. B.FAHRENBACH ETAL 3,200,718

CARTON FORMING MACHINE 9 Sheets-Sheet 5 Filed Nov. 14, 1962 INVENTORSWolfgang B. Fahrenbach BY Fred E. Helmick Attorneys Fig. 7

1965 w. B. FAHRENB ACH ETAL 3,200,718

CARTON FORMING MACHINE Filed Nov. 14, 1962 9 Sheets-Sheet 6 202 F i g. 9

Wolfgang B. Fahrenbacf BY Fred E. Helmick 67/44 (fie M29 Anarneys 1965w. B. FAHRENBACH ETAL 3,200,718

CARTON FORMING MACHINE Filed Nov. 14, 1962 Fig. IO

9 Sheets-Sheet 7 INVENTORJ Wolfgang B. Fahrenbach BY Fred Attorneys Aug.1965 w. B. FAHRENBACH ETAL 3,200,718

CARTON FORMING MACHINE Filed Nov. 14, 1962 9 Sheets-Sheet 8 Fig. l2

INVENTORS wary B. Fahrenbach BY Fre elmlck 5 /44 @ZIZQ Attorneys 1965 w.B. FAHRENBACH ETAL 3, 00,718

CARTON FORMING MACHINE Filed Nov. 14, 1962 9 Sheets-Sheet 9 5 V I L 46So! Sol Sol 2:; 3/0

F i g. [6 j} in 304 294 INVENTORS Wolfgang B. Fahrenbach BY Fred E.Helmick Attorneys United States Patent s,200,71 e CARTON FORMENG MACHINEu Wolfgang B. Fahreuhach, GaklandCalifi, and Fred E. Helmick, 381 FeltonDrive,,M'enlo' Park, Calif; said Fahrenhach assignor to said Helm'i'ck RFiled Nov. 14, 1962, Ser. No. 237,474 13 Claims. (Cl. 93-37) Thisinvention relates to carton forming machines and is concerned moreparticularly with the provision of an improved machine of this characteradapted to forming egg cartons of the type shown in Randles Patent2,946,497.

Successful automatic machines for'forming partitioned egg cartons havebeen developed heretofore, for example, the machines disclosed inRandles Patent 2,935,917 and in our Patent 3,015,256. Machines of thistype generally operate to push or to pull carton blanks through variousoperating stations in the machine which function to fold the blanks intothe final partitioned carton, and to discharge the same in propersequence for subsequent operations. While such machines are highlysuccessful, the necessity of feeding the blanks in endwise fashionthrough the machine requires careful attention to tolerances and tofeeding in proper sequence, to avoid jamming or choking of the machine.In addition, such machines require considerable space, and consequentlyare not readily adaptable to use with automatic egg candlers and gradersof the type disclosed, for example, in co-pending Scollard et al.application Serial No. 89,275, filed February 14, 1961, and similarautomatic machinery.

In general, it is an object of the present invention to improve uponcarton forming machines of the above character, particularly withrespect to means permitting carton blanks to be folded into completedpartition cartons directly out of a hopper for the blanks.

Another object of the invention is to provide a carton forming machineof such character capable of folding the blanks in a simple repetitiveoperation which requires a minimum of space.

Another object of the invention is to provide a carton forming machineof the above character employing improved means for folding the blanksand for forming and tucking the carton bottom and partitions.

A further object of the invention is to provide such a machine which isadapted to fully automatic or semiautomatic operations, and which iscapable of operating in carefully timed sequence.

Another object of the invention is to provide a carton forming machineof the above character which operates in cyclic fashion to pull a cartonblank directly from a feed hopper, to fold the same into a completedpartitioned carton, and to discharge the same directly from the hopperin a series of successive operating steps.

Other objects and advantages of the invention will be apparent from thefollowing description of the preferred embodiment thereof, asillustrated in the accompanying drawings, in which:

FIGURE 1 is a view in side elevation of a carton forming machineembodying our invention, showing its position in relation to automaticconveyor means adapted to convey completed cartons to other machinery.

FIGURE 2 is an enlarged plan view along the line 2-2 of FIGURE 1.

FIGURE 3 is a view in section and in elevation along the line 3-3 ofFIGURE 2.

FIGURES 4 to 6 are fragmentary schematic views along the line 44 ofFIGURE 2, illustrating steps in the operations of the blank feeding andfolding stations.

FIGURES 7 and 8 are like views along the line 3-3 of FIGURE 2,illustrating further steps in the operation of the blank feeding andfolding stations.

FIGURE 9 is a like View illustrating the operating sequence of thevarious stations, and particularly illustrating the operation of thedischarge mechanism at the moment of discharging a completed carton.

FIGURES l0 and 11 are plan views, similar to FIG- URE 2, illustratingsteps in the operation of partition forming means at the blank foldingstation.

FIGURES l2 and 13 are like views illustrating steps in the operation ofbottom tucking means at the blank folding station.

FIGURES 14 and 15 are enlarged detail views, illustrating the operationof the bottom tucking mechanism.

FIGURE 16 is a schematic view of a control system for the machine.

FIGURE 17 is a perspective view of a portion of the carton blank,illustrating the initial opening operation.

FIGURES 18 to 21 are views in elevation showing the sequence of stepsinvolved in folding the component parts of a formed carton intointerlocking engagement to form a completed partitioned carton.

In general, the carton forming machine of the present invention operatesin conjunction with a stack of prefolded, collapsed blanks positioned in.a hopper, and broad- 1y functions to fold one blank at a time directlyout of the hopper and into a completed partitioned carton. The completedcartons are discharged from the machine for conveyance to a fillingmachine wherein the cartons are filled with merchandise. As indicatedpreviously, the carton blanks employed in the machine can be of a wellknown prefabricated type having certain portions die cut and glued toother portions to form a blank suitably adapted to the operations of themachine.

The machine performs the specific functions of opening the carton blanksto a desired box shape, bending or folding a plurality of transversepartitions from one panel of the formed blank, and then folding andtucking an opposite or .bottom panel into interlocking engagement withthe partitions to form a completed carton. In the preferred embodimentof the machine illustrated, these operations are all performed at asingle folding station located immediately adjacent or beneath a hopperor feeding station Within the machine. A discharge mechanism, adjacentthe folding station, functions to simultaneously eject a formed cartonout of the folding station and downwardly away from the feed hopper ontoa carton arrestor. The latter deposits the carton in upright position ona discharge conveyor for delivery to subsequent operations.

Referring to the drawings in detail, 10 indicates a frame includingrespective side plates 12 and I4 (FIGURES 1 to 3) which are connectedadjacent the top by-angled transverse frame brackets 16 and 18, andadjacent the bottom by similar frame brackets 20 and 22, and by the baseframe 24. The latter provides a support for suitable means forming adischarge c-onveyer for the completed cartons, represented in FIGURE 1by the endless belt conveyer 26.

The machine frame It? provides a mounting for means forming variousoperating stations within the machine, including a blank feeding station3!) (FIGURES 3 and 4), a folding station 32 including operativelyassociated blank opening, partition folding and panel interlockingsub-assemblies 34, 36 and 38 (FIGURES 5 to 8), and a discharge mechanism4t (FIGURE 9). As will be described, the machine functions toperiodically engage a carton in lowermost position in the feedingstation 30, to open a forward portion thereof downwardly into thefolding station 32, and through operation of the opening, folding andinterlocking sub-assemblies to fold and tuck the opened portion of theblank into a completed partitioned carton.

FIGURE 16, is employed to exert continuous suction through .theaccumulator 44 and vacuum line as leading to the blank openingsub-assembly 32;, and through the vacuum line 48 leading to the variousoperating cylinders of the machine, as will be described. The machinecan also be designed to operate in conjunction with a positive pressuresystem for the operating cylinders, in which compressed air or othergaseous fluid, or, alternatively, oil, water, or other hydraulic fluidis used instead of the suction in line 48.

BLANK FEEDING STATION The blank feeding station 3t) (FIGURE 3) performsthe relatively simple function of supporting a stack of carton blanks5i) (FIGURE 4) in such fashion that the forward portion 52 of thelowermost blank in the stack can be opened downwardly for the subsequentoperations performed at the folding station. As best seen in FIG- URES 2and 3, the station 3ft comprises a pair of upstanding cylindrical guidemembers 54- which cooperate with the transverse frame bracket 16, andtoe plate as, to form shower. The cylindrical guides 54 are suitablysupported on the cross frame member 13 by the means 57. The frame 18also provides a support for the toe plate 56, which is mounted in spacedrelation between the upstanding guides (note FIGURE 2).

In the operations at the feeding station, the lowermost blank issupported at its forward edge by the toe plate 56, and by abutmentagainst the upstanding guide members 54 which are received within theslots 58 provided in the leading edge of the carton blank. This blank isalso supported by the transverse frame 16, at a point slightly to therear of its center of gravity. The remaining blanks in the stack aresupported upon the lowermost blank and by engagement with the upstandingguides 5'4, in the manner shown in FIGURE 4. This relationshipconcentrates a substantial portion of the weight of the stack upon theportion of the blank resting on the upper surface of the cross framemember to which, as will appear, functions as a fulcrum in thesubsequent folding operations. In general, the operations at the feedingstation 3d require the presence of several carton blanks within thehopper to insure a proper support and distribution of Weight upon thelowermost blank, adjacent the fulcrum 6d.

BLANK FOLDING STATION The folding station 32 (FIGURES 4 to 8) functionsto engage the forward portion 52 of each carton blank in success-ion asit reaches the lowermost position in the hopper at the feeding stationEll, and to bend it downwardly and subject it to the various forming,folding and tucking operations necessary to form the completed carton.These various operations are performed by the previously mentionedsub-assemblies which are associated with the folding station.Specifically, the opening or box forming sub-assembly 34- functions tograsp a lower portion of the blank and to bend it downwardly about thefulcrum point oil in such fashion as to fold lower collapsed portions ofthe blank into the desired hollow-box form. The partition formingsub-assembly 36 functions to bend a plurality of downthrust partitionsin the lower blank portion into a transverse attitude and to hold thesame in proper position during the operation of the interlockingsub-assembly 38. The latter sub-assembly functions to fold and tuck anopposed downthrust panel portion of the blank into interlockingengagement with the plurality of partitions to form the completedpartitioned carton Referring to FIGURES 17 to 21, it will be seen thateach carton blank comprises a main panel 62 which is die cut inpredetermined manner, and to which is secured along a gluing strip 64'extending transversely of the panel, a lower collapsed or folded portion66. This lower portion 66 is appropriately die cut so that, upon beingopened, a plurality of partitions 63 are provided which can be bent intoa transverse attitude, for example as in FIGURES 18 to 20. The lowerportion 66 is also provided with a foldable panel portion 7%? which isprovided with a plurality of segments adapted to be folded and tuckedinto engagement with the transverse partitions 65 to interlock the sameinto a formed completed carton, as represented in FIGURE 21.

Blank opening sub-assembly The blank opening sub-assembly 34 generallyemploys a plurality of suction cups '72, rigidly supported on a crosshead 7d. As best seen in FIGURE 2, the cross head is mounted for pivotalmovement on pivot shafts '75 carried by a pair of rocker arms 76. Thepivot shafts also carry rollers dd which cooperate with cam segments 82,84 mounted in spaced relation upon the side plates 12 and 14. Referringto FiGURE 3, the rocker arms 76 have bent arm portions $36 which arepivotally attached at 83 to the distal ends of cranks 9t} carried byactuator shafts )2 and 92a. The latter are in turn keyed for rotarymovements with sprockets 94 and 94a, engaged in chain drives 96 and 96a,on either side of the machine.

With particular reference to FIGURE 2, the sub assembly 34 is energizedby the operating cylinder lit-ll through the chain drive as. The pistonof this cylinder is connected to the lower reach of the chain, at 1&2,and functions through reciprocatory movements of the chain to impartreversible rotary movements to the drive sprocket 94, and to an idlersprocket 98. The latter is key d to the cross shaft 104, and serves torotate the corresponding idler sprockets 98a and drive sprocket 94a onthe opposite side of the machine. As particularly shown in FIGURES 4 to6, operation of the air cylinder 1% to retract the piston from anextended position will cause the cranks 99 to rotate in a clockwisedirection through an arc of approximately 130, due to rotation of thedrive sprockets 94, 94a and their stub shafts 92, 92w

Referring again to FIGURE 3, the suction head '74 is mounted on therocker arms 7s in such fashion that pivoting of these arms will causethe suction cups 72 to follow a prescribed opening path determined bythe cam segments 82 and 84. This operation is particularly shown in thesequence positions of the blank opening sub-assembly shown in FIGURES 4to 6. It will be noted that the cam followers on the ends of the rockerarms are held in engagement with the cam segments by means of springsres, attached at their inner ends to base portions of the cranks 9t andat their outer ends to the extending portions of the rocker arms 76. Asa result of this construction, actuation of the rocker arms initiallycauses the suction cups '72 to pull the forward end of the lowermostcarton blank downward off the toe plate, and forward, as the camfollowers 80 proceed along the flattened portions 108 of the upper camsegments 82. This operation, particularly illustrated by the sequencepositions-0f FIG- URES 4 and 5, initially releases the forward portionof the carton blank from the toe plate 56 in the feeding station, andadvances the entire carton blank a slight amount (represented at lit) inFIGURE 5) to properly align the blank for the subsequent opening andfolding operations. As the suction cups 72 follow the surfaces of thecam segments 32, 84, they function to open the carton blank downwardlyinto the desired hollow box formation shown in FIGURE 6. To insure thatthe suction cups are at all times properly oriented to the carton blanksduring these operations, the cross head 74 is provided with a verticallyextending pivot control rod 112, which is adapted to be received in anapertured guide element 114 mounted on the side plate 14. The shape ofthe control rod 112 is such that the pivot aspect of the suctionelements 72 at all times insures a maximum application of suction to thecollapsed portion 52 of the blank, to pull it downwardly and rearwardlyinto open position.

It will be understood that the vacuum line 46 (FIG- URES 3 and 16)exerts a continuous suction through each of the suction elements 72 sothat the latter immediately grasp a carton blank placed in lowermostposition in the hopper. This suction is only broken by subsequentoperations to fold the blank into the completed partitioned carton, aswill appear. It may be noted that the cross head 74 carries a pair ofupstanding fingers 115 which project through die cut openings 77 in thelowermost carton blank. These fingers assist in properly positioning theblanks in the feed station, in moving the lowermost carton forward priorto the opening operation, and in preventing the suction cups '72 fromslipping on the surface of the carton during the opening operation.

Partition folding sub-assembly The partition forming sub-assembly 34(FIGURES 2, 3, l0, and 11) comprises a plurality of partition engagingplates 12%) which are adapted to be moved in fore and aft and sidewisepivotal relation with respect to the folding station 32. Thissub-assembly is controlled by the air cylinder 122 which operates uponits return stroke to pivot a crank 124 about the cross shaft 126, andthereby impart a forward pivotal or rocking movement to the arms 12%carrying the partition engaging plates 120. As best illustrated inFIGURE 3, each of the arms 128 is internally recessed to pivotallyreceive a rod support 130 for the upper and lower segments of apartition engaging plate 129. The support rods 131 are additionallyprovided with rearwardly extending crank elements 132 con nected formovements in unison by means of a cross bar 134. The plates 12a arenormally held in the position shown in FIGURE 2 by means of a spring 13dattached to an arm 138 on one of the pivot rods 130 and to a screw 1% onone of the pivot arms 128. As particularly shown in FIGURE 2, theentering angle of the plates 12% is determined by cooperation of thespring 136 and an adjustable stop 142 carried on one of the pivot rods1315.

Referring again to FIGURE 2, at least two of the pivot rods 130 carrytripping levers 144 provided with adiustable contact members 146. Asillustrated in FIGURE 7, these members function upon forward movement ofthe pivot arms 128 to engage the cross support 16, and thereby to rotatethe rods 136i and plates 1219 in a clockwise direction (as viewed inFIGURE 2). It will be understood that this rotary movement (shown insequence in FIGURES l0 and 11) occurs only at the end of the forwardrocking movement of the pivot arms 128 (see FIG- URE 7), and that theamount of rotary movement is relatively small (compare FIGURES and 11).

Referring to FIGURES 18 to 20, the initial movement of the pivot arms(up to the moment of contact of the stop 146 with the cross frame 16),causes the plates 123 to engage and partially bend the partitions 68 asparticularly illustrated in FIGURE 19. Subsequent movement of the pivotarms 1228 causes the stops 145 to shift the cross bar 13%, so that eachof the plates 120 is rotated clockwise to deflect the partitions 68 intothe desired transverse positions shown in FIGURES 11 and 20, and also inFTGURE 7.

It will be noted that the crank 124 is provided with a rear extension123 to which is secured a valve operator 125 for a valve 127 in thevacuum line 4-6. Throughout the blank opening operation, and duringintermediate rest positions of the machine, it is desirable that thevacuum line exert a continuous suction through the cups 72. However,during the partition folding and bottom interlocking operations, it ispreferable to close the vacuum line to prevent interference throughaction of the suction cups. This is accomplished by movement of thecrank extensions 123 and valve operator to close the valve 127', as thepartition forming plates 1% are moved forward into engagement with theopened carton blank. During the partition forming operation, the forwardpressure of the plate 120 is resisted by the presence of the fingers 115within the openings 77 of the blank, and by the weight of the stack ofblanks upon the unfolded blank portion 210 above the fulcrum till. Aswill be explained, when the carton has been completely formed, thepartition forming sub-assembly is retracted causing the valve 127 toagain open, through the action of the spring 129, restoring suction tothe cups 72.

Bottom interlocking sub-assembly The sub-assembly 36 (FIGURES 2, 3, and8) functions to drive the foldable bottom panel 70 of the carton blankbetween and into interlocking engagement with the transverselypositioned partitions 68. This sub-assembly is operated by the aircylinder 15%, through the chain drives 152 and 152a, which impart to andfro planar movement of the operating components of the interlockingsubassembly.

As best seen in FIGURE 2, the chain drives 1522, 152a are supported onsprockets 1541, 154a mounted on suitable stub shafts provided in theside plates 12 and 1d, and sprockets 156, 156a carried by the crossshaft 158. The drive 152 is attached to the piston of the operatingcylinder 1513, at 159 (FIGURE 2).

in the illustrated apparatus, the interlocking subassembly comprises across head member 1&0 having ends 162 supported on the cooperating chaindrives 152, 152a. The cross head carries a plurality of sharpened driverelements 15 i, operable (in the full line position of FIGURE 8) to tuckthe segments of the foldable bottom panel '70 between the partitions as.The cross head also sup ports a slide member or interlocking device 166,which is slidably supported on headed pins 1nd protruding from the crosshead and received in slots 179 provided in the slide member. The latteris normally biased to the left, as viewed in FEGURE 2, by means of aspring 172 connected at one end to one of the pins 163, and at the otherto a pin 1'76 on the slide member.

As particularly shown in FIGURES 14 and 15, the slide member is actuatedby a trigger 17S pivoted on the cross head 1%, at 181 The triggerincludes a projecting crank 182 adapted to engage a flanged projection184 on the cross head 1%, and has a downwardly protruding flange 136adapted to engage an adjustable actuator 18% supported in appropriatelyspaced relation on the side plate 14. It may be explained that movementof the cross head 161) from an outthrust position on the chain drives(as represented in FIGURES 3, 4 and 10), to an initial tucking position(as represented in FIGURES 12 and 14) will cause the drivers 164 toforce the foldable segments of the panel 711 between the partition 68.However, as particularly shown in FIGURE 14, this initial movement doesnot necessarily interlock the tabs 199 of the bottom panel with theopenings 19 2 in the partitions. This latter function is achieved by thefinalrnovement of the cross head, which causes the trigger 173 to engagethe actuator 183 to shift the slide member 166 to the position shown inFIGURES 13 and 15. It will be noted that the slide member 166 isprovided with a flurality of teeth 194 which engage intermediateportions 196 of the partitions, forcing them sideways so that theprojections 19% enter and interlock within the openings 192 (noteFIGURES 20 and 21).

At this point in the operation, as will be more fully explained, thecylinder 150 operates to return the interlocking sub-assembly 38 to itsoriginal extended position, the air cylinder 122 operates to retract thepartition forming sub-assembly 36 and the cylinder 1% operates to pivotthe suction cups 172 of the blank opening sub-assembly 32 upward intocontact with the lowermost blank in the feed station 31). This sequenceof operations, illustrated sesame C by the arrows 2tl2 in FIGURE 9,properly positions the various sub-assemblies at the folding station 32to permit subsequent operation of the discharge mechanism 4G to ejectthe completed partitioned carton.

DISCHARGE MECHANISM As has previously been explained, only the forwardportion 52 of the lowermost carton blank in the feed hopper is openeddownwardly and formed and tucked into the body of a completed carton.The unfolded rear or cover portion 210 of the carton remains in positionbeneath the stack of cartons t and in frictional. engagement with theupper surface or fulcrum 66 of the cross frame 16. This relation isparticularly shown in Fl UR-ES 5 to 8.

The discharge mechanism 40 functions to engage the folded portions ofthe carton, and to pull the unfolded cover portion Zlltl from beneaththe stack of cartons 5t and thereafter. to eject the carton in uprightposition for deposit on the discharge conveyor 26. Referring to FIG- URE9, the discharge mechanism is seen to comprise a pair of upstandingpivot arms 220 supporting a pair of cross arms 226, and mounted forrotation on the cross shaft 222 by means of the bracket supports 224. Asillustrated in FIGURES 4 to 8, the upper cross arm 226 is normallypositioned adjacent the cross frame member where it assists this memberin forming the fulcrum 69. During the discharge operation, the arms 226engage the folded portions of the carton in the manner illustrated inFIGURE 9.

The mounting brackets 224 for the pivot arms are transversely connectedby means of a cross member which carries a lever 232 pivotally connectedto the piston of the operating cylinder 23b. The latter functions (onthe upstroke) to pivot the arms 22d downwardly to the dis chargeposition shown in the full lines in FIGURE 9, and immediately thereafter(on the downstroke) to return the discharge mechanism to its restposition. In the latter position, the machine is ready for foldingoperations to be performed on the next carton blank in sequence, as previously described.

The present machine is particularly adapted to providing a continuoussupply of open erect cartons to subse quent filling operations, forexample, as practiced with automatic egg handling and grading apparatusof the type disclosed in the aforementioned Scollard et al. applicationSerial No. 89,275. Successful operation of such machines depends upon avirtually continuous uninterrupted supply of cartons to insure that eggsor other merchandise are not fed to the filling station at a time whenno carton is present, or the carton is kicked over or otherwiseincapable of receiving. the merchandise. Accordingly, to insure that thecartons are discharged from the machine and deposited on the conveyor 26(FIGUME l) in continuous upright fashion, an arresting mechanism 2 stcan be provided.

In the illustrated embodiment, the mechanism 240 comprises a pair ofspring members 242 mounted on a cross shaft 243 and operable on thedownstroke of the discharge arms 220. This operation is accomplished bycontact between a kicker foot or actuating member 244 carried by themounting members 224 and adapted to engage an actuating lever 24%extending rearwardly from the cross shaft support 248 for the members242. As will be readily understood, the downstroke of the pivot arms 220will cause the spring members 242 to be elevated to the illustratedsolid line position, where they momentarily support the dischargedcarton. Upright guides d are also provided adjacent the supports 2% toproperly orient the carton. Upon return of the pivot arms 220 to theiruppermost or rest position, the supports 242 cooperate with the guides25th to gently deposit the carton upon the discharge conveyor 32, inupright position.

CONTROL SEQUENCE The operating sequence of the machine can beelectrically controlled, for example by means of the control circuitshown schematically in FlGURE 16. This circuit, in addition to supplyingpower to the vacuum pump 42, energizes an electric motor 26% for therotatably mounted cams 262., 26 i, 266, and 265i.

Operation of the machine is accomplished by depressing button 27 1),thereby energizing motor 268 to rotate the cams (clockwise as viewed inFEGURE i6). Cam 262 immediately depresses the switch 272 causing thesolenoid 274 to retract the spool valve 276 against the pres sure of thespring 278. This causes the valve to close the bleed port 2%, permittingthe vacuum pump %2 to bleed the valve through the lines 232. and 284 sothat the blank opening cylinder 11% operates to retract the chain drivefor the blank opening sub-assembly This latter operation is facilitatedby the simultaneous opening of the vent port 2526 so that air issupplied through the line 238 to the lower side of the cylinder i i-ti.Following the blank opening operation, cam 26 i operates in similarfashion through switch 290 and its associated solenoid and spool valveassembly, to retract the piston of air cylinder 122. As a consequence,the plates 5") of the partition forming sub-assembly 36 are advanced toform the partitions. immediately thereafter, the cam 2-66 actuates itssolenoid and spool valve assembly, in virtually identical fashion,causing the air cylinder 15% to actuate the bottom tucking mechanism.However, in this instance, the lines 2% and 298 are reversed so that thepiston of cylinder is extended rather than retracted.

At this stage in the operations, the blank opening subassembly 3 haspivoted downward to its openng position (FIGURE 6), the partitionopening sub-assembly 36 has moved forward to its holding position(FIGURE 7), and the bottom tucking sub-assembly has advanced to itstucking or interlocking position (FIGURE 8).

The cams 2&2, 26d, and 265 are so constructed that further rotation ofthe cam shaft causes the switches 2% and 272 to open and de-energize thesolenoids 21 4 in a reverse sequence. This causes the cylinder 15% toinitially operate to retract the bottom tuckiri mechanism, the cylinder122 to next return the partition opening plates to their back position,and, finally, the cylinder to return the suction cups of the blankopening subassembly to the up position. It will be understood that theseoperations are accomplished by return of the spool valves 276 to theirup position, to close the vent ports 23%) and open vent ports 286,thereby causing the vacuum pump 42 to bleed air from the lower ends ofthe cylinders 1% and 122, and the upper end of the cylinder 1%. Thisparticular sequence of operations is represented by the arrows 2th 2ti2and 294- in FIGURE 9.

With the parts shown in the full line positions of FIC- URE 9, continuedrotation of cam causes this carn to eventually close switch 3th Thelatter switch energizes solenoid M2 and spool valve Zitl in the mannerjust described, causing the air cylinder to swing the discharge assembly40 to its down or discharge position, as shown in FIGURE 9. However, thedimension of the cam projection is such that the switch 3th? is almostimmediately reopened, causing the cylinder 23b to return the dischargemechanism at to its up or rest position. The operating cycle of themachine is now complete, with the cams 262, 264, 265, 268 againpositioned to initiate the forming of an additional carton, by operationof the cylinders 1%, 122, 159, and 2 30 in the sequence noted.

Once the machine is started into operation, by depressing the button27tl, it will continue automatically to make and deposit cartons on thedischarge conveyer 26. However, it is desirable that some means beprovided, such as the switch 319 shown in FIGURE 1, whereby the machinewill cease making cantons when a sufilcient supply is on hand. As shownin FIGURE 16, contact with 9 the switch 31!) effects a break in thecontrol circuit so that the machine ceases to operate. In this fashionthe machine functions to fold cartons directly out of the feedingstation 30, in the quantities actually needed in the subsequent cartonfilling and closing operations.

MACHINE OPERATION Reviewing briefly the operation of the machine, it isassumed that the parts are in the positions illustrated in FIGURES 3 and4, and that a stack of carton blanks 50 has been placed in properposition within the hopper formed by the cross frame 16, toe plate 56and upright guides 54, at the feeding station 30. The dischargemechanism 38 is thus in position against the cross flange 16 where itassists in providing a folding fulcrum at 6t In the operating sequenceat the folding station 32, the piston of the air cylinder 100 isinitially extended by operation of the cam 252. This causes the chaindrives 96, 96a, to rotate the cranks 96 of the blank opening subassembly34 in a clockwise direction, and the arms 76 to rock forwardly anddownwardly, as particularly illustrated in FIGURES 4 to 6. The contactbetween the suction elements 72 and the lowermost carton blanksimultaneously pulls the forward end of the blank downward off the toeplate 56, and forward so as to properly position the rear of the blankupon the fulcrum 60. This operation corresponds with movement of the camfollowers 80 along the flattened portions 168 of the upper cams 8 2.Thereafter the rollers 80 follow the smooth curve of the cam surfaces82, 84, causing the collapsed portion of the carton to open into thehollow box configuration shown in FIGURE 6. Proper following of themovement of the rollers 89 is insured by the spring action of the rockerarm 76 about the pivot points 88 due to action of the springs 1636.During this operation, the pivot attitude of the suction cups 72 ismaintained in proper relationship to the wall of the opening cartonblank by means of the shaped control rod 112 received in the aperturedguide member 114. During subsequent operations at the folding station,the cam 262 functions to hold the piston of cylinder 1% in extendedposition, thereby insuring that the cross head 74 will remain in thedown or opening position. However, when the cam 264 operates to retractthe piston of the air cylinder 122 (to thereby rock the partitionforming subassembly in a forward direction, it also causes lever 124 andvalve actuator 125 to close the vacuum line to the suction cups '72. Thecylinder 122 simultaneously pivots the partition forming flaps 120forwardly to initially engage and partially open the partitions 68, asshown in solid lines in FIG- URE l9. Immediately thereafter, theactuators 146 strike the cross members 16 causing the pivot rods 130 andthe rearward extending levers 132 to pivot the plates 120 in clockwisedirection to deflect the partitions 63 sideways into the fully opened ortransverse position shown in full lines in FIGURE 7 and in FIGURE 20.During this operation the upstanding fingers '75 on the suction crosshead 74 hold the canton blank in proper position, against the pressureof the plates 120.

When the air cylinder 122 has completed its upstroke, the cam 266operates to shift the piston of cylinder 159 so that the chain drives152, 154 move the drivers 164 against bottom panel 70 of the carton.Thereafter the drivers force the segments of the panel 79 between thepartitions 68 to an initial position shown in FIGURE 14. At this pointthe trigger 178 for the shiftable tucking plate 166 engages theadjustable actuator 188, and shifts the slide member 166 to the right,to position shown in FIG- URE 15. The effect is to forcibly tuck thebottom panel projections 190 within the openings 192 of the partitions68, thereby locking these parts of the carton in assembled relation. Asthe sub-assembly 38 reaches the out-stroke of the cylinder 150, it isalmost immediately retracted (arrow 2% in FIGURE 9) through reversal ofthe cylinder 150, in response to continued rotation of the cam 266. Inlike fashion, the cam 264 acts to retract the partition formingsub-assembly 36 (arrow 202), and the cam 266 to return the blank openingsub-assembly 34 to its original position adjacent the cross member 16(arrow 294). During this sequence of operations, the valve 127 is againopened through action of the lever 124 and actuator 125, to inducesuflicient suction in the contact units 72 to positively grasp the nextblank in lowermost position within the feeding station 30.

When the various folding sub-assemblies have been returned to theiroriginal positions, shown in FIGURE 9, the completed carton isdischarged from the machine through cooperation of the dischargemechanism 40 (arrow 254), the arresting mechanism 242 (arrow 254), andthe discharge conveyor 26 (arrow 256). The discharge mechanism isactuated by the cam 268 which causes the cylinder 23% to swing the crossarms 226 against the folded portions of the carton, pulling theremaining unfolded portions out of the hopper, and thereafter to actuatethe arresting mechanism 240 to deposit the carton on the conveyor, inthe manner previously described. The completed carton is now dischargedfrom the machine, along with additional cartons in any desired quantity(depending on the spacing of the switch 10), on the conveyor 26.

From the foregoing, it will be apparent that the machine of theinvention not only requires a minimum of space in which to feed blanksand in which to discharge completed cartons, but also virtuallyeliminates the jamming normally associated with endwise movement ofblanks and cartons through the machines. Moreover, this trouble freeoperation can be rapidly and effectively accomplished in a very smallspace immediately adjacent a feed hopper by the simple operation ofpulling a. carton blank directly out of the feed hopper into a formingor folding station. There, the machine performs all of the blank openingand forming operations in a space scarcely larger than the completedcarton itself, and then discharges the carton by pulling remainingfolded portions from the hopper in such fashion that the carton can bedeposited upon a discharge conveyor running through the machine. Themachine is thus particularly well qualified for use in automated cartonforming and supplying operations associated with other automaticmachinery, and where available space is at a premium.

While the invention has been illustrated and described in connectionwith a preferred embodiment, it is capable of other variations andmodifications within the scope of the claims.

We claim:

1. In a machine for forming cartons: a feeding station includingupstanding guide means and a transverse support means forming a hopperadapted to receive a stack of pre-folded, collapsed, substantiallyplanar blanks; a carton folding station immediately below said feedingstation, said folding station including means to periodically engage acarton blank in lowermost position in said feeding station to open aforward portion thereof downwardly about said transverse support means,means to deflect a portion of said opened blank into partitions, andmeans to fold and tuck another portion of said opened blank between saidpartitions; said transverse support means resisting the movement of saidfolding and tucking means to permit the forming of said opened cartonportions into a completed partitioned carton, means for holding rearportions of said carton in the feeding station; and discharge meansadapted to engage said completed partitioned carton to pull the rearunfolded portions thereof from said hopper and to eject the same.

2. A carton forming machine as in claim 1 wherein said means toperiodically engage the lowermost carton blank comprises pivotallymounted suction elements and cooperating means operable to produce adownward and then a rearward movement of said suction elements whilemaintaining contact of the suction elements with the blank.

3. A carton forming machine as in claim 1 wherein i said discharge meansincludes pivotally mounted contact members normally positioned adjacentsaid transverse support member but pivotally operable to pull thecompleted partitioned cart-on forward and downwardly from the hopper insaid feeding station.

4. In a carton forming machine: a feeding station including guide meansforming a hopper adapted to receive a stack of prefolded collapsedcarton blanks; a carton folding station immediately below said station,said folding station including means to positively grasp a carton blankin lowermost position in said said feeding station to deflect a forwardportion thereof downwardly into a hollow box carton form, means to benda plurality of downthrust partitions of said blank into transverseattitude and means to fold and tuck an opposite downthrust panel of saidblank into interlocking engagement with said plurality of partitions toform a completed partitioned carton; and cooperating pivot means forminga stationary support in said folding station during said folding andtucking operations and thereafter a movable discharge means adapted toengage said completed partitioned carton to pull remaining unfoldedportions thereof from said hopper to eject the same.

5. In a carton forming machine: a feeding station including upstandingguide means and transverse support means forming a hopper adapted toreceive a stack of prefolded substantially planar carton blanks in saidhopper; a carton folding station immediately below said feeding station,said folding station including pivotally operable means to positivelygrasp a carton blank in lowermost position in said feeding station todeflect a forward portion thereof downwardly about said transversesupport means into a hollow box carton form, rear portions of said blankbeing held by the weight of said stack of blanks, means to bend aplurality of downthrust partitions of said blank into transverseattitude, and means to fold and tuck an opposite downthrust panel ofsaid blank into interlocking engagement with said plurality ofpartitions to form a completed partitioned carton; and pivotallyoperable discharge means normally positioned adjacent said transversesupport means so as to cooperate therewith but movable to engage saidcompleted carton and to pull the same forward and downward to pullremaining unfolded portions of said carton from said hopper, whereby thecompleted carton is ejected from the hopper.

6. A carton forming machine as in claim 5 wherein said means for bendinga plurality of partitions from the blank includes partition engagingcomponents to partially deflect the partitions, and delayed action meanscausing said partition engaging components to completely deflect saidpartitions into a transverse attitude.

'7. A carton forming machine as in claim 5 wherein said means to foldand tuck the opposite panel into interlocking engagement with thepartitions includes relatively movable members to first fold the panelinto engagement with the partitions and then to tuck the panel andpartitions into interlocking engagement.

8. A carton forming machine as in claim 5 wherein .E arrestor means andcooperating guide tioned adjacent said discharge mechanism to insuredischarge of completed cartons in a desired upright position.

9. In a machine for forming cartons: a feeding station including guidemeans forming a hopper adapted to receive a stack of prefolded collapsedcarton blanks; a carton folding station positioned immediately adjacentsaid feeding station, said folding station including means toperiodically engage a carton in lowermost position in said feedingstation and to pull the engaged portion down and then to the rear tothereby open the engaged blank portion into a hollow box configuration,means to deflect a portion of the opened blank to form partitions, andmeans to tuck another portion of said opened blank between saidpartitions to form an opened partitioned carton; and means to engage theopened folded portions of the carton and to eject remaining unfoldedportions thereof from said feeding station.

In a machine for forming cartons: a feeding station including guidemeans forming a hopper adapted to receive a stack of prefolded collapsedcarton blanks; a carton folding station positioned immediately adjacentsaid feecing station, said folding station including means toperiodically engage a carton blank in said feeding station and to open aportion thereof away from said hopper, means to deflect a portion ofsaid opened blank to form partitions, and means to fold and tuck afurther portion of said opened blank to interlocking engagement withsaid partitions; said folding station also including means to engage andhold the opened blank against the pressure of said folding and tuckingmeans; and discharge means adapted to engage and move the opened,interlocked carton away from said hopper to thereby eject the same fromsaid feeding station.

11. A carton forming machine as in claim 1% wherein said hopper iscomposed of front upstanding guides and a lower transverse supportmember providin an open hopper construction adapted to facilitateloading of blanks into the hopper at a relatively flat angle.

12. A carton forming machine as in claim 10 wherein said discharge meansto periodically engage a carton blank in said feeding station includespivotally mounted suction means and cooperating means operable toproduce a downward and then a rearward movement of said suction means toeffect opening of the carton blank.

13. A machine as in claim 9 wherein said discharge means cooperates inengaging and holding the opened deflected blank portions against thepressure of said folding and tucking means.

References Cited by the Examiner UNITED STATEs PATENTS 2,699,711 1/55Mobley 93-37 2,700,922 2/55 l'ordan 9337 3,015,256 1/62 Fahrenbach etal. 9337 FRANK E. BAILEY, Primary Examiner,

means are posi-

1. IN A MACHINE FOR FORMING CARTONS: A FEEDING STATION INCLUDINGUPSTANDING GUIDE MEANS ANDA TRANSVERSE SUPPORT MEANS FORMING A HOPPERADAPTED TO RECEIVE A STACK OF PRE-FOLDED, COLLAPSED, SUBSTANTIALLYPLANAR BLANKS; A CARTON FOLDING STATION IMEDIATELY BELOW SAID FEEDINGSTATION, SAID FOLDING STATION INCLUDING MEANS TO PERIODICALLY ENGAGE ACARTON BLANK IN LOWERMOST POSITION IN SAID FEEDING STATION TO OPEN AFORWARD PORTION THEREOF DOWNWARDLY ABOUT SAID TRANSVERSE SUPPORT MEANS,MEANS TO DEFLECT A PORTION OF SAID OPENED BLANK INTO PARTITIONS, ANDMEANS TO FOLD AND TUCK ANOTHER PORTION OF SAID OPENED BLANK BETWEEN SAIDPARTITIONS; SAID TRANSVERSE SUPPORT MEANS RESISTING THE MOVEMENT OF SAIDFOLDING AND TUCKING MEANS TO PERMIT THE FORMING OF SAID OPENED CATONPORTIONS INTO A COMPLETED PARTITIONED CARTON, MEANS FOR HOLDING REARPORTIONS OF SAID CARTON IN THE FEEDING STATION; AND DISCHARGE MEANSADAPTED TO ENGAGE SAID COMPLETED PARTITIONED CARTON TO PULL THE REARUNFOLDED PORTONS THEREOF FROM SAID HOPPER AND TO EJECT THE SAME.